Method and apparatus for handling and registering webs for forming packages

ABSTRACT

METHODS AND APPARATUS FOR FORMING FILLED PACKAGES FROM A FIRST WEB HAVING FILL POCKETS THEREON AND A SECOND COVER WEB HAVING MARKINGS FOR REGISTRATION WITH THE POCKETS ARE DISCLOSED HEREIN. THE POCKETED AND MARKED WEBS ARE BROUGHT TOGETHER AND INTERMITTENTLY OR STEP-BYSTEP ADVANCED IN THE FORMATION OF PACKAGES AND TENSIONING OF THE MARKED COVER WEB IS EMPLOYED TO EFFECT REGISTRATION OF THE MARKINGS THEREON WITH THE POCKS OF THE FURTHER WEB. ABRUPT TENSION CHANGES IN THE MARKING BEARING COVER WEB, COMMONLY RESULTANT FROM THE STEP-BY-STEP ADVANCING OF SUCH WEB, ARE REDUCED BY FEEDING THE COVER WEB IN SYNCHRONISM WITH THE ADVANCING OF BOTH WEBS AND AT A POINT PRECEDING THE APPLICATION OF THE COVER WEB TO THE POCKETED WEB.

Jan. 19, 1971 J. M. MILLER 3,555,765

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMINGPACKAGES Filed Feb. 26, 1968 5 Sheets-Sheet 1 JOHN M. M\L.LER

ATTORNEYS Jan. 19, 1971 J. M. MILLER 3,555,?

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMINGPACKAGES 5 Sheets-Sheet 2 F iled Feb. 26, 1968 INVENTOR JOHN M. MILLERJan. 19, 1971 J. M. MILLER 3 METHOD AND APPARATUS FOR HANDLING ANDREGISTERING WEBS FOR FORMING PACKAGES Filed Feb 26, 1968 5 Sheets-Sheet3 INVENTOR JOHN M. MLLLER BY fla F y M g w/mu TTOR N EYS Jan. 19, 1971J. M. MILLER 3,555,?

METHOD AND APPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMINGPACKAGES Filed Feb. 26, 1968 5 Sheets-Sheet 4.

FIG.5

INVENT OR JOHN M.M\LLER ORNEYl J. M. MILLER Jan. 19, 1971 METHOD ANDAPPARATUS FOR HANDLING AND REGISTERING WEBS FOR FORMING PACKAGES 5Sheets-Sheet 5 ,Filed Feb. 26, 1968 I I l l l II J 5 mg" 5% I @[bQ r mfiN wxfim 228: q 1. mm mud :6: 35 06% 33' hy em 5585 5581a INVENTOR JOHNM. M\L.LER

AMA??? @mmm United States Patent 3,555,768 METHOD AND APPARATUS FORHANDLING AND REGISTERING WEBS FOR FORMING PACKAGES John M. Miller, MountVernon, Ohio, assignor to Continental Can Company, Inc., New York, N.Y.,a corporation of New York Filed Feb. 26, 1968, Ser. No. 708,000 Int. Cl.B65b 7/16, 57/04; B31b 49/00 US. CI. 5339 21 Claims ABSTRACT OF THEDISCLOSURE Methods and apparatus for forming filled packages from afirst web having fill pockets thereon and a second cover web havingmarkings for registration with the pockets are disclosed herein. Thepocketed and marked webs are brought together and intermittently orstep-bystep advanced in the formation of packages and tensioning of themarked cover web is employed to effect registration of the markingsthereon with the pocks of the further web. Abrupt tension changes in themarking bearing cover web, commonly resultant from the step-by-stepadvancing of such web, are reduced by feeding the cover web insynchronism with the advancing of both webs and at a point preceding theapplication of the cover web to the pocketed web.

The invention relates generally to package forming machines whereinfirst and second webs are brought together and joined to form a seriesof fill containing packages, and more particularly to machines of thetype in which a marking bearing cover web and a pocket bearing furtherweb are advanced intermittently or in step-by-step fashion and joined toform packages wherein the markings and the pockets are correctlyregistered.

In the past, package forming machines have been provided wherein firstand second webs of heat scalable plastic material are provided onrelatively large supply rolls to be joined together in the formation offill containing packages. Commonly, fill pockets are provided in a firstof the webs while fill identifying or advertising markings are providedon the other web which is joined with the pocket containing *web to formsealed fill containing packages, marked in accordance with consumerrequirements. Inasmuch as it is often required that the markings ordesigns provided upon a cover web be exactly located or registered withthe fill pockets of the further web, it has been necessary to providearrangements whereby the location of cover web markings with respect tothe location of the pockets provided in the web to which the cover is tobe applied is carefully monitored and controlled for exact registrationbetween the desired markings and the fill accommodating pockets.

Inasmuch as it is never possible to provide exactly equal spacing of thepockets provided in one of the webs and the markings provided upon theother of such webs such as to maintain constant registration of themarkings and pockets without some drift during the employment of apackage forming machine, it has been suggested that the markingsprovided upon the cover web be given a spacing somewhat less than thespacing of the pockets provided in the further web such that when thetwo webs are joined in a package forming process, the markings of thecover web will tend to advance slightly with respect to the pockets. Inthis type of suggested registration system, the tension applied to thecover web during the joining together of the cover web and the pocketedfurther web is controlled so as to stretch the marking bearing cover webwhenever the markings thereon tend to advance beyond an acceptable limitof registration. In one such "ice suggested system, first and secondtension levels are made available for application to the cover webwhereby the first of such tension levels is not quite sufiicient tocause the spacing of the markings to equal the spacing of the pockets,while the second tension level is sufiicicnt to stretch the web to apoint at which the spacing of the markings exceeds the spacing of thepockets. In this type of system, application of the cover web to thepocketed web while the cover is maintained at the lower level of tensionprovides a gradual creeping forward of the markings of the cover webwith respect to the pockets of the further web, while the employment ofthe second, higher tension level is effective to cause the pockets ofthe pocket bearing web to move forward in position with respect to themarkings. Constant surveillance of the relative positions of themarkings and pockets is maintained, as through the use of aphoto-electric sensor or electric eye employed to control the level oftension applied to the cover web.

Employment of systems of the aforementioned types and the pockets inpackaging machines wherein both and the sprockets in packaging machineswherein both such webs are continuously fed from relatively large websupply rolls. However, numerous packaging machines employ intermittentor stcp-by-step feeding of the package forming webs wherein each of thewebs is abruptly advanced during a portion of a package forming cycleand abruptly halted and maintained immobile during a further part ofsuch cycle. As will be apparent, the abrupt pulling forward from asupply roll of a web which by its nature stretches under tension, causesabrupt inertial tension changes detrimental to the employment oftensioning of such a web for the aforementioned purposes. Thus, itbecomes difficult to employ differential tensioning of a cover web toeffect the correct registrations of markings provided thereon where suchweb is repeatedly pulled forward by the advancing mechanism of thepackage forming machine inasmuch as abruptly increased tension isexhibited by such cover web during the initial forward movement of thecover web in a particular cycle and further inasmuch as web relaxationis exhibited during the portion of the package forming cycle wherein theweb is again brought to rest.

The abrupt pulling forward or jerking forward of the cover web asdescribed hereinabovc further may result in a shearing or deformation ofthe web due to the suddenly increased tension thereon and such increasedtension coupled with intermittent periods of relaxation commonly resultsin wrinkling of the cover web at its point of application to theremaining package forming web. Application of a braking force to thecommonly employed web supply rolls such as to prevent the relaxation ofthe cover web is rendered difficult by the changes in inertia resultantfrom the reduction of web maintained on the supply rolls and attemptshave been made to provide a displaceable idler roll or dancer rollintermediate the package forming machine and the web supply rolls so asto provide a small web inventory which is drawn off during each cycleand which is sufficient to prevent the abrupt tensioning of the coverweb at the beginning of each cycle. However, the provision of dancerrolls in the web path increases the difficulty of applying tension tothe cover web to effect proper web marking registration inasmuch as arelatively slack portion of web is provided in the web feed path.

In accordance with the foregoing, then, it is an object of thisinvention toprovide methods and apparatus capable of controlling thetensioning of a web in an intermittently driven or step-by-step drivenpackage forming machine.

Similarly, it is an object of this invention to provide methods andapparatus for facilitating the registering of markings printed upon afirst web with fill-accommodating portions of a second web wherein thefirst and second webs are joined together to form a filled package andwherein both such webs are intermittently advanced during packageformation.

A further object of this invention is to provide package formingmachines of the type employing a step-by-step or intermittent webadvancing drive, cover web feed provisions driven in synchronism withthe Web advancing drive to avoid abrupt tensional changes in the coverweb in the area thereof intermediate the web advancing drive and thecover web feeding provisions.

Additionally, it is an object of this invention to provide cover webfeeding provisions of the foregoing type wherein feeding of the coverweb occurs prior to application of the cover web to the additional weband wherein such feeding is at substantially the same web feed speed asthe web feed speed of the web advancing drive.

It is yet another object of this invention to provide cover webtensioning provisions in combination with cover web feedings provisionsof the aforementioned types such as to control the tensioning applied tothe cover web to effect registration of markings on the cover web withfill accommodating portions of the remaining web.

Still another object of this invention is to provide tensioning of acover web through the employment of magnetic brake provisions incombination with tension controlling cover web feed provisions in astep-by-step web advancing package forming machine.

It is a further object of this invention to provide the tensioning of acover web through the employment of first and second cover Web feedprovisions and driving means coupled with the feed provisions forproviding differences in the web feed speed of each such feed provisionsso as to effect tensioning of the cover web intermediate the feedprovisions and in combination with a step-by-step web advancing packageforming machine.

Further still, it is an object of this invention to provide methods andapparatus for registering cover web markings with fill accommodationportions of a further web during the joining together of such webs inthe formation of filled packages by the step-by-step advancing of bothwebs through the application of repeated abrupt forces thereto and bythe application of a variable tension to the cover web sufficient tostretch the cover as required in the registration of the markingsthereon with the fill accommodating portions of the additional web andby continually feeding the cover web in synchronism with the advancingthereof to effect a reduction in the abrupt tensioning in the cover webresultant from the step-by-step advancing thereof.

With the above and other objects in view that will hereinafter appear,the nature of the invention will be more clearly understood by referenceto the following detailed description, the appended claims, and theseveral views illustrated in the accompanying drawings.

In the drawings:

FIG. 1 is a fragmentary side elevational view of package making machinestructure in accordance with this invention, and illustrates webadvancing provisions, cover web supply provisions and a cover web feedmechanism driven in synchronism with the web advancing provisions.

FIG. 2 is an enlarged fragmentary side elevational view of a portion ofthe structure shown in FIG. 1, and illustrates in greater detail coverweb tensioning provisions and cover web feed rolls forming part of thecover web feeding mechanism.

FIG. 3 is an enlarged fragmentary perspective view of a portion of theapparatus illustrated in FIG. 2 and shows in greater detail a cover webtensioning roll for applying a pretermined amount of tension to thecover web and a pair of cover web feed rolls for engaging the cover webpreceding its joinder with a further web and for 4 feeding the cover webin synchronism with the advancing provisions of the package formingmachine.

FIG. 4 is an enlarged fragmentary cross-sectional view of the severalrolls of FIG. 3, and shows the relative positioning of the cover webtensioning and feeding provisions and the mounting of these provisionson the side thereof not illustrated in FIG. 3.

FIG. 5 is an enlarged fragmentary vertical cross-sectional viewillustrating one form of a portion of the Web advancing provisions ofthe packaging machine.

FIG. 6 is a diagrammatic circuit illustration showing web tensioncontrol provisions suitable for controlling the tension applied to thecover by the web tensioning arrangements illustrated in FIGS. 1-4.

FIG. 7 is an enlarged fragmentary side elevational view of an alternatecover web tensioning arrangement, and shows first and second cover webfeed rolls and a speed differential drive coupled to the first andsecond fees rolls for varying the tension applied to the cover we FIG. 8is a diagrammatic circuit illustration of control provisions suitablefor controlling the tension applied to the cover web through the use ofthe tensioning arrangement illustrated in FIG. 7.

Referring to the drawings in detail, there is illustrated generally at10 in FIG. 1 a package forming machine of the type to which theinvention may be applied and wherein a first web 11 is drawn into themachine for the forming of fill accommodating pockets therein. The web11 is preferably thermoplastic in nature and is supplied from a suitablyprovided supply roll (not shown). A suitable pre-heating means 12 isprovided proximate the web 11 adjacent its point of entry into themachine 10 to allow pocketing of the web 11 by a set of verticallyreciprocable mold provisions 13 into which the web 11 is drawn for theformation of the pockets therein. A further set of verticallyreciprocable mold provisions 14 are provided for holding the pocketsrecently formed in the mold 13 against deformation upon engagement ofthe mold 14 with such recently formed pockets. Filling of the pockets-ofthe web 11 may be effected manually or by suitable automatic fillingprovisions capable of employment in combination with the over-allpackage forming machine 10. A cover web 15 is entrained into engagementwith the pocketed web 11 adjacent a cover web engaging roll 16. Thecover web 15 is, of course, entrained into engagement with the pocketedweb 11 for the covering of the pockets subsequently to the filling ofthe pockets with the desired commodity. Upon engagement of the cover web15 with the pocketed web 11, heat-sealing of the two webs is effectedthrough the utilization of vertically reciprocable heat sealers 17 andaligned web back-up provisions or plates 18.

In package forming machines of the type generally referred to by thenumeral 10 in FIG. 1, web advancement is of an intermittent orstep-by-step nature and the advancement of the pocketed web 11 in thisfashion imparts step-by-step advancement or intermittent movement to thecover web 15 by reason of the sealed together engagement of the webs 11and 15.

Drive provisions for the machine 10 include a suitably selected drivemotor 20 connected in driving engagement as at 21 with the inputprovisions 22 of a power transmission unit 23 coupled to a drive shaft24. The drive shaft 24 provides an input to a suitably chosen stepper orindexing mechanism generally indicated at 25. The stepper mechanism 25provides a step-by-step or intermittent motion output to the webs 11 and15 via an output shaft 26, and an output sprocket 27 engaging a firstdriven chain member 28 which is entrained about a driven sprocket 30rotatably mounted by a shaft 31 journaled for rotation in a shaftmounting trunnion 32. An additional sprocket 33 is mounted upon therotatable shaft 31 and is in driving engagement with a.- webconveyingchain 34 which extends longitudinally along the machine and which isentrained at the other end thereof about a further suitably selectedsprocket (not shown).

Transverse severing of the individually filled and covered packageforming pockets is effected at and longitudinal severing of transverselyspaced packages is effected through utilization of the cuttingprovisions indicated at 36. Thus, individual filled packages aredelivered from the package forming machine 10 via a discharge chute 37for the subsequent handling thereof.

Step-by-step advancement of the pocketed web 11 and the cover web 15 iseffected, as best illustrated in FIG. 5 through the employment ofsuitable web engaging means. generally referred to by the numeral 40carried by the intermittently driven web advancing chain 34. Asillustrated in FIG. 5, the web engaging means 40 may include first andsecond web clamping members 41 and 42 and means for biasing the clampingmembers into clamping engagement With the joined webs 11 and 15, as forexample, the spring bias means 43 in biasing engagement between thepivotally mounted clamping member 42 and the lower clamping member 41.Actuation of the pivotally mounted clamping member 42 into and out ofclamping engagement with the joined webs may be effected throughsuitable cam actuating provisions (not shown) or alternate provisionssuitable for effecting movement of the pivotally mounted member 42 intoclamping engagement with the periphery if the joined webs and release ofthe joined webs for discharge from the package forming machine 10. Asfurther illustrated in FIG. 5, the intermittently driven chain 34 may beguided in its movement relative to the path of conveyance of the webs 11and 15 through the provision of suitable guide roller means generallyindicated by the numeral 44.

Returning to FIG. 1, the cover web 15 is supplied from a cover websupply roll 45 suitably journaled upon a roll stand 46 which, in turn,is supported upon a frame superstructure 47 afiixed to and above theframework of the machine 10. Overrunning of the web supply roll 45 isprevented by a supply roll brake means 48, illustrated more fully inFIG. 2.

The supply roll 45 is supported upon a shaft 50, journaled for rotationby the roll stand 46 and the shaft 50 has afiixed thereto a gear 51 inengagement with a further brake gear 52 which, in turn, is afiixed to afurther shaft 53 which also is journaled for rotation by the roll stand46. A braking disk 54 is affixed to the shaft 53 and a brake shoe 55frictionally engages the periphery of the disk 54 to restrain movementof the supply roll 45 via the geared engagement of the gears 51 and 52.The brake shoe 55 is biased into engagement with the periphery of thebraking disk 54 by the interpositioning of a compression spring 56intermediate the shoe 55 and a brake shoe mounting bracket 57.Adjustment of the force applied to the braking disk 54 via the brakeshoe 55 is provided through the inclusion of manual adjustment means 58.

Tensioning of the cover web 15 is provided by the inclusion of a rubbersheathed main tension roll 60 mounted upon a shaft 61 journaled forrotation by a pair of side plates 62 of the frame super-structure 47.

The side plates 62 are provided with downwardly opening slots 63 whichallow removal of the roll 60 upon detachment of a pair of shaft supportbearing means 64. The shaft 61 is provided with a knob 65 allowing themanual movement of the tension roll 60.

An idler roll 66 is supported between the side plates 62 adjacent thetension roll 60 for movement with the web 15. A rubber sheathed presserroll 67 is located adjacent the main tension roll 60 opposite the idlerroll 66 and the presser roll 67 has its ends trunnioned at 68 in thefree lower ends of a suspension frame 70, said frame 70 including anintermediate connecting bar 71 and having free swinging support at 72 onthe plates 62, as illustrated in FIGS. 2 and 3.

A cross bar 74 is fixedly supported between the plates 62 and extendsparallel to the rolls 60, 66 and 67 and threadedly receives anchor rods75 having knurled manually operable adjuster nuts 76 thereon. The rods75 are connected to the forward ends of tension springs 77, as shown inFIGS. 2 and 3, and the other ends of the springs 77 are connected at 78to the bar 71 of the swingable frame 70. The springs 77 constantly urgethe presser roll 67 against the main tensioning roll 60, and the degreeof tensioning pressure may be readily adjusted by turning the knurlednuts 76. An idler roll 80 is mounted on the frame 24 forwardly of thetension rolls as best shown in FIGS. 2 and 3, and a further idler roll81 is mounted on the plates 62 beneath the supply roll 45. It will beapparent from FIGS. 2, 3 and 4 that the cover web 9 passes down from thesupply roll 45 under the guide or idler roll 81 and under the tensioningpresser roll 67, upwardly over the main tensioning roll 60 and downunder the idler roll 66, thus presenting a bight 79 of the web over themain tensioning roll 60 between the aforementioned rolls 66 and 67 asclearly shown in FIG. 2. From the idler roll 66, the cover web 15 passesupwardly over the idler roll 55 and thence downwardly toward thelocation of application of the cover web 15 to the pocketed web 11.

A magnetic brake unit 82 is supported at 83 on the super-structure 47,as best shown in FIGS. 1 and 2, and the brake unit 82 includes a rotorshaft 84 having a sprocket 85 fixed thereon and chain coupled at 86 witha sprocket 87 fixedly connected to the main tensioning roll 60. Themagnetic brake unit 82 applies controlled drag or braking action on themain tensioning roll 60 via the chain coupling 86 to resist drawing offof the cover web 15 from the supply roll 45 as the web 15, beingheat-sealed to the pocketed Web 11, and the pocketed web are movedalong.

The aforementioned magnetic brake unit may be a commercially availableunit, as for example the units available from Vickers, Incorporated,Electronics Product Division of St. Louis, Mo. It is relatively wellknown that this type of brake has its projecting rotor shaft attached toan inner member enclosed by and rotating with an outer member, bothmembers being independently supported by stator bearings and beingseparated from each other by a space or gap which remains constant. Saidgap contains finely divided dry ferromagnetic particles. A stator coilis included and when said coil is not energized the magnetic particleswithin the gap have insignificant frictional or binding effect, but whenthe stator coil is energized, a magnetic film is produced in the gap andproduces the bonding or braking action which is proportional to theapplied energizing current. Controlling of the degree of energizationwill, of course, control the degree of braking action which will beapplied to the tension roll 60 by the brake unit 82. It will be apparentthat this braking action may also be modified somewhat by the adjustmentof the tension springs 77, and also by the adjustable application of thebrake shoe 55 against the braking disk 54, as best shown in FIG. 2, butthis last-mentioned braking action serves principally to preventoverrunning of the roll 28 at the ends of the successively appliedstepping movements of the pocketed web 11 with which the cover web 15 ismoved along and drawn off the web supply roll 45.

The cover web- 15 has provided thereon a series of markings along thelength thereof to be registered with the pockets formed in the pocketedweb 11. Preferably, the markings provided upon the cover web 15 areprinted short. 'That is, the markings to be registered with the pocketsof the web 11 are spaced along the length of the cover web 15 at aspacing normally lesser than the spacing of the pockets along the lengthof the web 11. Tensioning of the cover web 15 by means of the magneticbrake unit 82 and the main tensioning roll 60 is employed to provide astretching of the cover web 15 such that the markings applied theretomay be registered with the pockets at the point of application of thecover web to the pocketed web 11 adjacent the roll 16. Preferably, afirst tension is insuflicient to increase the spacing of the level isapplied to the web 15 which tension level markings provided upon thecover web for exact registration with the pockets formed in the web 11.Thus, application of the cover web 15 while the cover web is tensionedat the first tension level results in an advancement of the markings onthe web 15 relative to the pockets of the web 11. Once the markings uponthe cover web 15 have advanced a predetermined amount relative to thepockets, a second higher tension level is applied to the cover web 15sufficient to stretch the cover such that the markings applied thereonare given a spacing greater than the spacing of the pockets with whichsuch markings are to be registered. Accordingly, application of thecover web 15 under the second higher tension level results in anadvancement of the pockets of the web 11 relative to the markingsprovided upon the cover web 15 until, again, the advancement of thepockets with respect to the markings reaches a predetermined maximum, atwhich time the first and lower tension level is again applied to thecover web 15.

Monitoring of the registration of cover web markings with respect to thepockets of the web 11 is provided, as will be more fully discussedhereinafter, through the employment of suitable sensing means, generallyreferred to by the numeral 90, which, as shown, may include a suitablelight source and photo-electric cell combniation 91. 92 mounted upon theframe super-structure 47 intermediate the tensioning rolls 60, 66 and 67and the point of application of the cover web 15 to the pocketed web 11adjacent the idler roll 16.

The continual intermittent or stepping advancement of the cover web 15as imparted thereto by the stepping mechanism results in an abrupttensioning of the cover web 15 at the beginning of each cycle orstepping movement of the cover web and further results in a slackeningof the cover web 15 each time the intermittently applied advancing forceis terminated. Such abrupt increases and decreases in the tensioning ofthe cover web 15 will be readily appreciated from a realization that theweb supply roll 45 exhibits a relatively large mass when a largequantity of cover web is maintained thereon and, accordingly, each timethe cover web 15 is jerked forward the static inertia tending tomaintain that web immobile must be overcome, while each time the coverweb 15 is halted in its advance, the kinetic inertia of that web mustagain be overcome.

As will be apparent, the abrupt increases and decreases in thetensioning of the cover web present difficulties in the employment oftensioning of the cover web to provide correct registration of markingsthereon with the further web 11. Additionally, distortion and/ orwrinkling of the cover web at its point of application to the pockets ofthe pocketed web must be avoided. A cover web feed means generallyreferred to by the numeral 93 is provided at a location preceding theapplication of the cover web 15 to the pocketed web 11. The cover webfeed means 93 positively feeds the cover web 15 in synchronism with theadvancing of the over-all package forming machine 10 and at essentiallythe same speed as that imparted to the cover web via the advancingstep-by-step drive provisions of the machine 10. Thus, abrupt tensioningand slackening of the cover web 15 intermediate the cover web feed means93 and the point of application of the cover web to the pocketed web issubstantially reduced or elimnated inasmuch as the cover web 15 ispositively fed into the package forming machine 10 as required duringeach cycle of that machine, thus allowing no abrupt speed differences inthe cover web 15 intermediate the cover web feed means 93 and thelocation at which such cover web is applied in completing theindividually formed packages. Similarly, the monitoring or sensingprovisions 90 do not respond to undesirable abrupt tension levelalterations but,

rather, the sensing or monitoring means respond only to the location ofthe markings upon the cover web 15 as determined by the tension at whichthe cover web 15 is fed into the area intermediate the cover web feedmeans 93 and the point of application of the cover web to the pocketedweb.

As shown in FIGS. 1, 2 and 3, the cover web feed means 93 may include apair of cover web feed rolls 92 and 93 supported upon the framesuper-structure 47 intermediate the idler rolls 80 and 16. A first ofthe cover web feed rolls 92 is fixedly mounted upon a shaft 94 journaledfor rotation, as by the bearing support means 95 mounted upon thesuper-structure support member 96. The feed roll 92 engages the coverweb 15 and is rotatably driven to positively feed the web 15 by asprocket 97 mounted upon the shaft 94, or similarly provided in positivedriving relation with the feed roll 92. An elongate driving chain member98 is entrained about the sprocket 97 and is driven in step-by-step orintermittent motion by the advancing apparatus of the package formingmachine 10. As best shown in FIG. 1, the elongate chain 98 may beentrained about a further sprocket 100 fixedly mounted upon a shaft 101which further fixedly supports a sprocket 102 in driven engagement withthe web advancing chain 34.

The second of the cover web feed rolls 93 is freely rotatably journaledadjacent the driven feed roll 92 opposite the path of movement of thecover web 15 as by the shaft 103 supported in suitable movable mountmeans 104 located upon the support member 96. The freely rotatable feedroll 93 is biased toward the driven feed roll 92 to firmly engage thecover web 15 in the nip between the two rolls as through the provisionof spring bias means 105. The rolls 92 and 93 may be of suitablyselected resilient or semi-resilient material or may be sheathed inrubber such that positive feed engagement with the cover web 15 iseffected.

The light source 91 of the monitoring means 90 is supported upon theframe super-structure 47 to project a control means across the path ofmovement of a series of control marks 107, best shown in FIG. 2,provided in predetermined spaced arrangement upon the cover web 15 andin predetermined positional relation to the markings provided upon thecover web 15 which are to be registered with the pockets formed in thepocketed web 11.

The continuously driven shaft 24 which provides an input to the steppermechanism 25 has afiixed thereto a pair of control cams 108 and 109 asbest seen in 'FIG. 1. The cam 108 is disposed to control a normally opensignal cut-out switch indicated at 111 in FIGS. 1 and 6 and the cam 109is disposed to control a normally closed re-set switch indicated at 112.

Registration of the cover web markings with the pockets provided in thepocketed web will best be understood by reference to FIG. 6 wherein apair of power supply lines L1 and L2 are shown in association with amains supply switch or breaker MS.

The cover web monitoring provisions 90 including the light source 91 andthe photo cell may include any of a number of suitably chosencommercially available scanner provisions, as for example, thecommercially available #341 Dietz Scanner, in association with asuitably chosen control amplifier 113 such as, for example, the readilycommercially available Dietz AD amplifier. Because the amplifier 113 iswidely commercially available and relatively well known, no detailedreference will be made to the construction thereof, however, referencewill be made to the amplifier actuated relay contacts 114, commonlyemployed in amplifier-photo-cell combinations of the type shown in FIG.6.

A circuit relay CR is included across the supply lines L1, L2 in serieswith the amplifier controlled relay contacts 112 and the relay CR, whenenergized and deenergized, will respectively open and close the contactsCR1 and Electrical energizing sources T and T are provided in parallelacross the lines L1, L2 and may comprise variable transformer means orvariable voltage divider means T serving to supply an input forconditioning the magnetic brake 82 for applying the aforementioneddesired predetermined definite low tension and stretch to the cover web15, and T serving to supply an input at a value for conditioning themagnetic brake 82 for applying the aforementioned predetermined definitehigher tension and stretch to the web 15. It is to be understood thatthe supply provisions T and T may be suitably selected from any of anumber of well known provisions capable of providing predeterminedvoltage conditions as required by the magnetic brake unit 82 employed.

Closure of the circuit relay CR effects a closing of contacts CR toapply the first predetermined input from T to the magnetic brake 82 viaa current limiting resistor 115 and a full wave rectifier arrangement116. Similarly, closure of the contacts CR effect energization of themagnetic brake 82 at an input level provided by T A manual r-e-setswitch 117 is shown in series with the normally closed cam actuatedswitch 112 for use in setting up and/or testing, or re-establishingnormal operation of the web registering provisions.

Preferably, application of an input to the magnetic brake 82 from theinput provisions T provides the aforementioned less than sufficienttensioning level in the cover web such that the markings upon the coverweb are not stretched sufficiently to obtain an exact registration withthe pockets in the pocketed web 11. Thus, when the brake 82 is energizedfrom T a gradual creeping forward of the markings on the cover web withrespect to the pockets of the pocketed web 11 is apparent. Similarly,upon application of a second input from T to the magnetic brake 82,tension upon the cover web 15 is increased and a gradual retreat of themarkings on the cover web 15 with respect to the pockets of the web 11is apparent.

Each control mark or spot 107 (FIG. 2) preferably cuts or blocks thebeam of the sensor 90 during early motion of the web in a given feedcycle. The signal cutout cam 108 closes its associated switch 111 justas a properly registered given control mark 107 cuts or blocks thescanner beam. Closure of the switch 111 renders the scanner-amplifiercombination ineffective, maintaining the relay CR unenergized wherein alow-level input from T is applied to the magnetic brake 82 to maintainthe low tension level in the cover web 15. However, should the mark 107out the scanner beam prior to the closure of the switch 111, disruptionof the beam will effect closure of the contacts 114, thus energizing therelay CR to apply a second T input to the magnetic brake 82 via thenowclosed relay contacts CR As will be apparent, attention to the lengthof the dwell of the cam 108 which effects closure of the normally openswitch 111 will determine the acceptable limits of the positioning ofthe cover web borne marks 107 during each machine cycle.

Upon termination of the stepping motion of the webs 11 and 15, or afterthe mark 107 has safely passed the scanner beam, the cam 108 allowsreopening of the switch 111 such that the switch 111 will be openedprior to the pulling forward of the webs 11 and 15 during the nextsucceeding machine cycle.

The cam 109 effects closure of the switch 112 to provide opening of theamplifier relay contacts 114 to allow operation of the contacts 114through the actuation of the normally open switch 111 and thephoto-electric monitoring provisions 90 during the next succeedingmachine cycle.

As before stated, the tension applied to the web 15 by the magneticbrake 82 when that brake is energized via T to apply a low tension tothe web 15, should be sulficiently high that some stretching of the web15 will occur. This lower tension may bring the cover web 15 close toregistration such that the tensioning of the cover web 15 at the highertension level need not be extreme. Preferably, each of the lower andhigher tension levels should be applied to the cover web 15 for a numberof successive machine cycles rather than having both the lower andhigher tensions applied to the cover web 15 during each cycle or duringeach successive cycle.

Turning to FIG. 7, there is shown therein an alternate tensioningarrangement wherein provisions similar to those discussed hereinaboveare given similar reference numerals. A cover web 15' is supplied from acover web supply roll 45' to'the over-all package forming machine whichmay be of the type designated at numeral 10 in FIG. 1. The supply roll45 is mounted upon a shaft 50" journaled for rotation upon a supply rollstand 46 which, in turn, is supported upon a frame super-structure 47'afiixed to the framework of the over-all machine as discussedhereinabove with respect to the frame super-structure 47.

Braking provisions, generally designated 48, are provided upon the rollstand 46' to reduce over-running of the supply roll 45 and the brakingprovisions 48' may be of the type discussed hereinabove with respect toFIG. 2 or may, as shown, include a pair of pivotally mounted shaftengaging brake members 120 and a threaded manually adjustable member 121threadedly engaging the pivotal members 120 for adjusting the brakingforce applied to the shaft 50'.

The cover web 15 is entrained downwardly and about an idler roll 81'journaled for rotation by a pair of support plates 122, one of which isshown in FIG. 7, mounted upon the frame super-structure 47. A pair offeed rolls 123, 124 are mounted upon a pair of shaft .125, 126,journaled for rotation by the plates 122 and the feed rolls 123, 124engage the cover web 15' in the nip therebetween and in feeding relationto the cover web. The web 15 passes from between the nip of the feedrolls 123, 124 about a further idler roll supported for rotation by theframe super-structure 47 and an additional pair of feed rolls 92, 93engage the cover web in feeding relation preceding the application ofthe cover web to the pocketed web 1.1.

The feed rolls 92, 93' are similar in nature to the feed rolls 92, 93discussed hereinabove, relieving abrupt tensional forces and slackeningof the cover web 15 intermediate the feed rolls 92', 93' and the pointof application of the cover web 15 to the pocketed web. The feed roll92' is driven in synchronism with the web-advance mechanism of theover-all package forming machine through the provision of an elongatechain member 98', driven from the advancing provisions of the machineand entrained about a sprocket 97 affixed to the feed roll 92' forrotation therewith.

Once again, the feed rolls 124, 125 and 92', 93' may be of resilient orsemi-resilient material or may be rubber sheathed to provide goodfeeding engagement with the cover web 15'. The feed roll 93 is shownbiased into engagement with the cover web by a resilient member and thefeed I011 124 may similarly be so biased.

Prior to the application of the cover web 15 to the pocketed web, thepositional relationship of the markings provided upon the cover web 15'with respect to the pockets of the pocketed web is monitored'by amonitoring means 90', including a light source 91' and a photoelectriccell 92 positioned to scan across the path of movement of marks 107provided upon the cover web 15'.

The feed roll 123 is driven from a sprocket 126, mounted upon the shaft125 and in driven engagement with a drive chain 127. The drive chain 127is entrained about a sprocket 128 fixed to an output shaft 130 of aspeed differential drive unit 131. A first input to the speeddifferential unit 131 is provided by a shaft 132 having a sprocket 133aflixed thereto. An input drive chain 134 engages the sprocket 133 toimpart input drive rotation thereto and the chain 134 is entrained abouta further sprocket (unnumbered) afiixed to the driven feed roll 92.Thus, the speed differential unit 131 receives an input synchronizedwith the advancing of the webs .11 and by the step-by-step advancingmechanism of the over-all package forming machine.

Speed differential units of the type shown in FIG. 7 are readilycommercially available, as for example from Fairchild-HillerCorporation, Industrial Products Branch, West Babylon, Long Island, NY.The speed differential unit 131 shown in FIG. 7 includes a suitablychosen commercially available differential gear box having, in additionto the input shaft 132 an output shaft 130*, a further input shaft 134to which is coupled a suitably selected commercially available motor 135for providing a second input to the gear box to determine the drivenspeed of the output shaft 130*. Application of an input to the shaft 132via the input drive chain 34 and its associated sprockets provides anoutput at the shaft 130 to provide feeding of the cover web 15' via thechain 127 and the driven feed roll 123. As will be apparent to onesskilled in the art, the dimensions of the sprockets 126 and 128 and thediameter of the feed roll 123 may be selected to provide a web feedspeed from the feed roll 123 identical to the feed speed provided by thefeed roll 92 and the feed roll 123 may be driven at a slightly lesserspeed than the feed of the feed roll 92 by application of an input at134 to impart the higher than normal level of tensioning to the coverweb 15' in which case the web 15 will be stretched sufficiently toprovide registration of the markings thereon with the pockets of thepocketed web in a fashion similar to that discussed hereinabove withrespect to the utilization of first and second, lower and higher levelsof cover web tensioning. Application of an input to the second inputshaft 134 of the speed differential unit 131 in a reverse direction mayalso be provided by the motor 135 to increase the web feeding speed ofthe feed roll 123 to provide a relaxation of the tension level in thecover web 15' intermediate the feed rolls 123 and 92 such that the spacing of markings is reduced from a predetermined maximum. It will, ofcourse, be apparent to ones skilled in the art that the rnotor 135 maybe coupled to the input shaft 134 to provide an increase in speed of thefeed roll 123 such that the motor 135 would normally be energized whenthe lower tension level is to be applied to the cover web 15' and themotor 135 would be deenergized to result in a slowing of the feed rateapplied to the feed roll 123 from the differential unit 131 when thesecond, higher tension level is desired.

FIG. 8 indicates generally the geared relation of the input and outputshafts of a suitably selected differential gear box employable as thespeed differential unit 131. An input applied to the shaft 132 istransmitted to the output shaft 130 inasmuch as the shafts 132 and 130are coupled together via the gearing provisions 136 diagrammaticallyillustrated in FIG. 8. An input applied to the second input shaft 134from the motor 135 is applied to the output shaft 130 in addition to therotation imparted thereto by the input shaft 132. Thus, the rotationaloutput speed at shaft 130 will be increased or decreased by theapplication of a further input at the shaft 134, dependent upon thedirection of rotational input at 134.

FIG. 8 further shows the utilization of control provisions, similar tothose shown in FIG. 6 as discussed hereinabove, suitable for controllingthe input applied to the secondary input shaft 134 of the speeddifferential unit 131. A pair of supply lines L1 and L2 are connected tosuitably chosen supply provisions by a mains supply switch MS and asource T is connected across the lines L1, L2 to provide an input to themotor 135 via a pair of relay uontrolled contacts CR to impart rotationto the input shaft 134 upon a determination that an increased tensionlevel is required of the cover web 15. The photocell light sourcecombination of the scanner or monitoring means is essentially similar tothose provisions as discussed in relation to FIG. 6 and the amplifier113', amplifier relay contacts 114', circuit relay CR and the switches111', 112' and 117 are also similar to the similarly referencedprovisions of FIG. 6. The cam actuated switch 111' is cyclically drivenfrom a cam of the type shown in FIG. 1 at 108 and interception of thelight beam provided by the light source 91 by the registering mark 107prior to the closure of the cam actuated switch 111' effects closure ofthe amplifier relay contacts 115' to energize the relay CR, whereuponthe motor will be energized via the relay contacts CR Where as in FIG.8, the secondary input to the differential unit 131 at 134 isunidirectional, the feed speed at rolls 123 and 124 provided normally byapplication of a sole input at 132 may be equal to or less than the feedspeed at rolls 92' and 93' depending upon the degree of relaxation ofthe web prior to its entrance between the first feed rolls.

Additionally, it will be apparent the motor 135 may be normally drivenin a first direction to provide a first feed speed at rolls 123 and 124equal to or greater than the feed speed at rolls 92' and 93, in whichcase reversing of the motor may be employed to decrease the feed speedat rolls 123 and 124.

The switch 117' is manually operable for use in setting up automaticregistration control and the cam actuated switch 112 is driven from acam of the nature of the cam 109 shown in FIG. 1 to re-set the amplifierrelay contacts 115' preceding the beginning of each machine cycle.

Once again, the cover web 15 is, preferably, printed short and the feedroll 92' may be driven in synchronism with and at the same speed as thespeed imparted to the joined web via the machine-included web advancemechanism. Tensioning of the cover web 15' is imparted to the Web in theportion of the web intermediate the feed means including the feed rolls92' and 123. A feed speed imparted to the feed roll 123 which is equalto or slightly greater than the feed speed of the driven roll 92' willresult in a moving forward of the web borne markings away fromregistration with the pockets in the associated pocketed web. As thecover web markings creep forward with respect to the associated pockets,a point will be reached wherein the cutting of the beam from the lightsource 91 by one of the marks 107' will effect energization of the motor135 to decrease the speed of the feed roll 123 driven from the output ofthe differential gear box. Thus, a tensioning will be applied to thecover web 15' at a higher level, increasing the markings providedthereon to a spacing greater than the spacing of the associated pocketsand the markings applied to the pockets will gradually tend towardperfect registration.

The methods of providing web registration and the structures andstructural relationships employed in such methods as disclosed hereinrepresent preferred forms of the invention, however, it will be readilyapparent that variations may be made in the structures set forth withoutdeparture from the scope and spirit of the invention as defined by theappended claims.

I claim:

1. In a machine for forming filled packages from a filled pocketcontaining web having spaced pockets along the legnth thereof, webadvance means for step-by-step advancing a first web having spacedpockets formed along the length thereof, means for applying to said weba cover web having thereon repeated marking patterns along the lengththereof for registration with the pockets, the patterns being spacedapart less than the spacing apart of the pockets, means for applyingtension to said cover web to increase the spacing of said patterns to aspacing greater than the spacing of the pockets, tension controllingfeed means for engaging the cover web prior to the application thereofto the first web for stepby-step advancing the cover web in synchronismwith the step-bystep advancing the cover web in synchronism with thestep-by-step advancing of the first web to reduce abrupt tensioning ofthe cover web intermediate said feed means and the point of applicationthereof to said first web and drive means interconnecting said webadvance means and said feed means for driving said feed means from andin synchronism with said advance means.

2. A machine according to claim 1 wherein said feed means comprises apair of web feed rolls engaging the cover web in the nip therebetween ata location spaced from the point of application of the cover web to thefirst web, said rolls insulating the cover web at the point ofapplication from abrupt inertial tension changes resulting from thestep-by-step movement of the cover web.

3. A machine according to claim 1 wherein said drive meansinterconnecting said web advance and feed means comprises means fordriving said feed means at substantially the same web-feed speed as thefeed speed of said web advance means.

4. A machine according to claim 1 further comprising registrationsensing control means responsive to the disposition of the patterns onthe cover web with respect to the pockets of the first web forcontrolling said means for applying tension.

5. A machine according to claim 1 wherein said means for applyingtension comprises second Web feed means for engaging said cover web at alocation spaced from said tension controlling feed means, said drivemeans comprising speed differential drive means connected in drivingrelation to said tension controlling feed means and said second web feedtneans for providing differing web-feed speeds to both said tensioncontrolling feed means and said second web feed means to increase anddecrease the tension on the cover web.

6. A machine according to claim 5 wherein said speed differential drivemeans comprises input means, means interconnecting said input means,said web advance means and said tension control feed means, output meansconnected to said second web feed means for driving said second web feedmeans and means for varying the output speed of said output means.

7. A machine according to claim 6 further comprising registrationsensing control means responsive to the disposition of the patterns onthe cover web with respect to the pockets of the first Web forcontrolling said means for "varying the output speed of said outputmeans of the speed differential drive means.

8. In a machine for forming filled packages from a firsit filled pocketcontaining web having spaced pockets along the length thereof and acover web having thereon repeated markings to be registered with thepockets, web advancing means for step-by-step advancing said first andcover webs in a continual series of abrupt movement, means for applyingsaid cover web to said first web, means for applying tension to saidcover web to stretch said cover web to provide spacing of the repeatedmarkings thereon at least as great as the spacing of the filled pocketsof said web, tension controlling feed roll means for engaging said coverweb in feeding relation at a location preceding the application of saidcover web to said first web and drive means interconnecting said webadvancing means and said feed roll means for driving said feed rollmeans in step-by-step synchronism with said web advancing means, saidadvancing means and feed roll means being spaced apart along the lengthof said cover web for driving said cover web at substantially equal feedspeeds to reduce inertial tenison changes in the cover web portionextending between said advancing means and said feed roll means.

9. A machine according to claim 8 wherein said means for applyingtension comprises electrically controlled magnetic brake means engagingsaid cover web preceding the engagement of said cover web with said feedroll means.

10. A machine according to claim 9 wherein said means for applyingtension further comprises mark sensing means electrically connecting tosaid brake means for controlling said brake means in response to therelative disposition of the cover web markings with the filled pocketcontaining portions of the first web.

-11. In a machine for forming filled packages from a first filled pocketcontaining web having spaced pockets along the length thereof and acover web having thereon repeated markings to be registered with theportions, web advance means for step-by-step advancing said first andcover webs in a continual series of abrupt movements, means for applyingsaid cover web to said first web, means for applying tension to saidcover Web to provide spacing of the repeated markings thereon at leastas great as the spacing of the portions of said first web, tensioncontrolling first feed roll means for engaging said cover web in feedingrelation at a location preceding the application of said cover web tosaid first web, drive means interconnecting said web advance means andsaid first feed roll means for driving said feed roll means, said meansfor applying tension comprising second feed roll means for feeding saidWeb at a location spaced from said first feed roll means, and speeddifferential drive means interconnecting said first and second feed rollmeans for controlling differences in the feed speed of said first andsecond feed roll means to vary the tension in said cover webintermediate said first and second feed roll means.

12. A machine according to claim 11 wherein said speed differentialdrive means comprises an input shaft driven from said web advance means,an output shaft in driving connection with said second feed roll meansand means for varying the output speed of said output shaft.

13. A machine according to claim 12 wherein said first feed roll meansis driven from said Web advance means for feeding said cover web insynchronism and at the same speed at said web advance means, said meansfor varying the speed of the speed differential means output shaftcomprising means for decreasing the feed speed of said second feed rollmeans to a feed speed lesser than the feed speed of said first feed-rollmeans to increase tension on said cover web intermediate said first andsecond feed roll means.

14. The machine according to claim 13 wherein said means for varying theoutput speed has electrically connected thereto mark sensing means forcontrolling the feed speed of said second feed roll means in response tothe relative disposition of the cover web markings with the fillaccommodating portions of said first web.

15. The method of registering cover Web markings with filled pockets ofa further web during the joining together of the webs in a packageproducing process comprising the steps of advancing step-by-step thecover and further webs by the application of repeated abrupt forcesthereto at a first location, joining the webs, applying variable tensionto the cover web and to stretch the cover web and increase the spacingbetween the markings thereon, continually feeding the cover web insynchronism with the step of advancing and at a further location removedfrom the first location in a direction Opposite the direction of webadvance and said step of feeding comprises imparting a web feed speed tothe cover web at the further location substantially equal to the feedspeed provided by said step of advancing stepby-step to reduce inertialtension changes in the web intermediate the first and second locations.

16. The method according to claim 15 wherein said step of feedingcomprises providing a cover web feed roll, engaging the roll with theweb at the further location and driving the roll step-by-step insynchronism with and at substantially the same feed speed as the step ofadvancing.

17. The method according to claim 16 wherein the 15 step of tensioningcomprises applying a braking force to the cover web prior to the joiningof the webs.

18. The method according to claim 17 further comprising the step ofmonitoring the position of the markings on the cover Web with respect tothe positions of the pockets of the further web and altering thetensioning applied in said step of tensioning to effect registrations ofthe markings and the fill portions.

19. The method according to claim 15 comprising the additional step offeeding the cover web at a third location and varying the feed speedapplied at the third location to provide variations in web tensionintermediate the third and further locations.

20. The method according to claim 19 wherein the step of feeding thecover web at the further and third locations each comprise providing afeed roll, engaging the feed roll with the cover web at the further andthird locations, said step of applying variable tension comprisingdriving the feed rolls at differing speeds to apply tension to the coverweb intermediate the feed rolls.

21. The method according to claim 20 further comprising the step ofmonitoring the position of the markings on the cover web with respect tothe positions of the fill portions of the further web and altering thefeed speed of the feed roll at the third location to alter thetensioning applied in said step of tensioning to efiect registration ofthe markings and the pockets.

References Cited UNITED STATES PATENTS 3,411,767 11/1968 Moser 9335(PC0)Re. 25,736 3/1965 Willbrandt 5351 2,214,593 9/1940 Mustin (sheet 1) 5351X 3,238,691 3/1966 Miller 533 3,267,639 8/1966 Ollier (sheet 1) 53513,276,183 10/1966 Carlisle 5351 3,294,301 12/1966 Richter 535 1X3,405,501 10/ 1968 Edelberg 5364X 3,427,778 2/ 1969 McCluskey 5333,453,799 7/1969 Cloud (last page) 535 1X WAYNE A. MORSE, JR., PrimaryExaminer US. Cl. X.R.

